klm safe commiss - rev 3

8/3/2019 KLM Safe Commiss - Rev 3

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KLM TechnologyGroup Sdn. Bhd.

Practical Engineering Guidelinesfor Processing Plant Solutions

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#03-12 Block Aronia Phone +60 60 07-241-8396 Jalan Sri Perkasa 2 Email: [email protected] Taman Tampoi Utama Internet: www.kolmetz.com 81200 Johor Bahru, Malaysia

Guidelines for Safe Pre-commissioning, Commissioning, andOperation of Process Units

Introduction

The success of every company depends of each employee's understanding of the keybusiness components. Employee training and development will unlock the companies'profitability and reliability. When people, processes and technology work together as ateam developing practical solutions, companies can maximize profitability and assets in asustainable manner. Training and development is an investment in future success - giveyourself and your employees the keys to success

It is strategically important that your operations team understands the fundamentals of process unit operations concepts. This is the difference between being in the best quartileof operational ability and being in the last quartile. There is vast difference in theoperational ability of operating companies and most benchmarking studies haveconfirmed this gap in operational abilities.

Whether you have a team of new or seasoned employees, an introduction or review of

these concepts is very beneficial in closing the gap if you are not in the best quartile, ormaintaining a leadership position. Most studies show that a continuous reinforcement of best practices in operational principles is the most effective way to obtain the desiredresults. Training and learning should be an on going continuous life long goal.

Course Objective

This course will guide the participates to develop key concepts and techniques to pre-commission, commission, operate and troubleshoot key fundamental unit operationsystems. These key concepts can be utilized to make operating decisions that can improveyour units performance.

Many aspects of operations can be improved including, product recoveries, purities andenergy utilization, and safety. This cannot be achieved without first an understanding of basic fundamental principles of design and operation. These principles need to be


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#03-12 Block Aronia Phone +60 17-731-6875Jalan Sri Perkasa 2 Email: [email protected] Taman Tampoi Utama Internet: www.kolmetz.com 81200 Johor Bahru, Malaysia

understood in advance of operating and trouble shooting a process unit operation for the

operator or problem solving to be effective.This seminar focuses on the core building blocks of the process unit equipment. Thisprogram will emphasize process unit equipment fundamentals, safe utilization of thesefundamentals by operations and maintenance personnel, and equipment troubleshootingtechniques. This program can be 3-5 days depending on the needs analysis of theparticipants.

Outline

Day One

Introduction

Overview of the Chemical Processing Industry Chemistry of the Processing Industry

Review of Process Incidents

Safety for the Operation and Maintenance Groups

Basics Process Equipment Review

Furnaces Boilers and Steam Systems Steam Turbines, Pumps and Compressors Towers and Vessels Piping Pressure and Temperature Limits Heat Exchangers


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Day 2

Basics Process Equipment Review Continued

Electrical Systems Reactor Systems Process Utilities Systems Relief Valve and Flare Systems

Review of Hazard Analysis Techniques

Hazard Identification

- energy sources- electrical sources- chemical sources

Case Study on Hazard Identification HAZOP System Methods Root Cause Analysis Methods Case Study on Root Cause Analysis Incident Investigation

Day 3

Building Commissioning Guidelines

Industry Resources Industry Best Practices Acceptable Guidelines

Building Commissioning Plan

Review Guidelines Scheduled Commissioning Activities Estimate Cost from Activities

Safe Equipment Isolation Guidelines


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General Hazardous Work Guidelines

Line Breaking Guidelines Vessel Opening Guidelines Confined Spaces Guidelines Excavation Guidelines Electrical Guidelines TLV Threshold Limit Values Case Study on Isolation Systems

Day 4

Safe Equipment Isolation Labels Guidelines

Labeling of Isolation Systems Lockout, Tag and Try

Safe Equipment Isolation Industry Standards

Examples of Industry Standards Guidelines Examples of Industry Standard Labels

Troubleshooting Guidelines

Problem Analysis Troubleshooting Techniques

Project Management Overview

Project Management Guidelines Contingency Planning Balancing Technical, Mechanical, and Time Constraints

Conclusions

Who is the Captain of Your Ship? Building Safety Awareness


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Who Should Attend: People who are making day to day decisions regarding operation, design, and

economics of processing plants;

1. Operation Supervisors,2. Maintenance Supervisors,3. Senior Plant Supervisors,4. Operations Engineers5. Process Support Engineers,

Ideal for veterans and those with only a few years of experience who want toreview or broaden their understanding in Processing Plant Operations.

Other professionals who desire a better understanding of subject matter

What you can expect to gain:

The Process Unit Equipment Fundamentals how each system functions from ahands on viewpoint

Safe commissioning and utilization of process equipment Safe de-commissioning of process equipment

Hazard Analysis Techniques

Safe Isolation Guidelines

Project Management Guidelines

klm safe commiss - rev 3

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